Insulated Partition for Use in a Building

ABSTRACT

A zipped insulated partition allows entry and exit through a building opening, but once closed, prevents drafts and energy loss from a house or commercial building into its attic (and other energy losing openings such as crawl spaces). The insulated partition improves upon the insular quality and upon safety as is it can be operated from the stairs or a ladder with one hand. The partition is permanently installed and airtight. It is toughly made and protects its insulation layer, and it is designed to have a variable R-factor.

This application claims the benefit of U.S. Provisional Patent Application No. 62/408,297, filed Oct. 14, 2016, also entitled “Insulated Partition for Use in a Building”, which is incorporated by reference herein in its entirety.

The present invention relates to the field of insulation devices for insulating a building. Specifically, the device described herein includes a zipped, insulated partition that allows entry and exit between building spaces, but once closed, the partition prevents drafts and energy loss through an attic door, for instance, or alternatively for other energy losing openings in a building including conditioned crawlspaces, entries, and whole house attic fans that remain open.

BACKGROUND

Buildings often have openings such as doors or window inserts that are notoriously inefficient in terms of thermal insulation. For instance, attic stairways, whether pull-down or permanent, can be extremely energy inefficient. Pull-down attic accessways have historically been made with a thin (⅜ or ½ in) sheet of plywood with no insulation. They are drafty and unsealed and allow significant energy loss during both the summer and winter months.

There have been efforts to try to solve this sort of problem of leaky building openings. Many known devices are not permanently installed nor are they substantially airtight. For instance, devices are made from foam board and do not create a true airtight seal. While they may offer some help in reducing energy loss, they are still leaky. Other devices are not a laminate of multi-purpose materials, and they can lack the durability required in an opening that may be regularly accessed. In some examples, devices use textiles that may tear or rip when and if they come into contact with the attic ladder or a hinge or something a homeowner might be moving around in the attic storage space. In the specific example of an attic opening, other devices must be installed from within the attic, which can present installation challenges. Other devices are made from materials with a short useful life such as cardboard or upholstery foam.

Some known devices make use of a thermally reflective layer. However, the devices that do have a reflective layer do not protect the reflective layer as it is exposed. This is disadvantageous, because it is easy to tear or otherwise damage that reflective layer and render it less efficient.

Finally, existing devices have a fixed amount of insulative value associated with them. This may prevent a user of a prior device from meeting regulatory requirements including the current IRC 402.2.4 and IECC requirements that mandates new construction attic hatches and attic pull down ladders, for instance, maintain the same r-value or insulative value as the area surrounding the attic hatch opening. Because of the variances in application and interpretation of these regulatory requirements, different partitions would have to be engineered for different specific, geographic locations.

SUMMARY

It is an object of the present invention to overcome the foregoing drawbacks of existing insulating partition devices. In one example described herein, partition covers improve on the insular quality, air sealing capability, and ease of installation of opening covers. The partition disclosed herein improves upon existing designs as it is designed to enable a variable r-factor to be chosen by the installer regardless of what the controlling insulation code is for attic hatches and other accessways and openings. Further, the partition structure does not leave the thermally reflective layer exposed to tearing or other abuse. The partition structure improves upon resistance to tearing and tensile strength upon other products. The partition structure improves upon safety over products that require a balancing act on the attic stairs or a ladder to put a foam board door back in an opening while standing on a ladder to get it closed. It is permanently installed and airtight and the more delicate reflective layer is protected by two or more outside protective layers. In one example, the partition uses a simple zipper for opening and shutting.

In one example, an insulated building partition comprises a multilayer sheet sized to cover an opening in a building, the sheet having a perimeter defined by the outside edge of the sheet. The sheet comprises an insulated cover, a flange, and a fastener strip. The insulated cover has a first inside layer of thermally reflective material between two outside protective layers of moisture resistant and relatively air impermeable materials. The flange comprises the portion of the sheet that begins at the perimeter of the sheet and extends inwardly from the perimeter around the sheet to an inside of the flange. The fastener strip is positioned between the insulated cover and the flange around at least a majority of the perimeter of the sheet, the fastener strip allowing the insulated cover to be both separated from and alternatively secured to the inside of the flange. One of the two outside protective layers has a supplemental attachment mechanism positioned thereon, wherein the supplemental attachment mechanism is adapted to secure a second insulating material to the outside of the outside protective layer of the cover, whereby an insulation rating of the partition may be varied depending on the amount of second insulation material that may be secured to the partition. The insulated cover may further comprise a first insulating layer positioned in between the outer protective layers and adjacent the thermally reflective material layer. The insulated cover may further comprise a second inside layer of thermally reflective material positioned on the opposite side of the first insulating layer from the first thermally reflective material layer. The thermally reflective material layer may be selected from the group consisting of a metal foil, a metal-coated polymer film, and a reflective bubble material. The outside protective layers may be formed of a material selected from the group consisting of knitted, woven or nonwoven fabrics and films formed from natural or synthetic materials including polyethylene, polyester, polypropylene, vinyl, cotton, hemp, and composites and mixtures thereof. The fastener strip can be a zipper or a hook and loop fastener structure. The flange may comprise three layers including two outside protective layers around an inside thermally reflective material layer. The supplemental attachment mechanism may be selected from the group consisting of a pocket, strap, sleeve, hook and loop fastener, snaps and hooks. The fastener strip may be a zipper having a two-sided zipper tab.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a top perspective view of an example of an insulated partition as described herein.

FIG. 2 is an environmental perspective view of an insulated partition as installed around an attic stair opening and in an opened position.

FIG. 3 is a side, cross-sectional view of one example of the insulated sheeting material used in the partition device described herein.

FIG. 4 is a side, cross-sectional view of a second example of the insulated sheeting material used in the partition device described herein.

FIG. 5 is a side, cross-sectional view of a third example of the insulated sheeting material used in the partition device described herein.

FIG. 6 is a perspective view of an insulated partition having straps for securing additional insulating material to the partition.

FIG. 7 is a perspective view of an insulated partition having pockets for securing additional insulating material to the partition.

DETAILED DESCRIPTION

Buildings including homes and commercial structures will often have some openings designed into them that are potential energy-loss locations. These openings may include attic stairways, crawlspace access doors, attic fans, air conditioner window units, uninsulated utility rooms, laddered entryways to commercial roofs, and any other efficiency weak spots. The device described herein is a durable insulated partition that is made up of an insulated cover having at least three layers. The outside protective layers are secured around an inside layer that includes a thermally reflective material and, optionally, other insulative features. The outside layers are formed of moisture resistant and relatively air-impermeable materials that are also tough enough to withstand regular consumer use and inadvertent abuse. The inside, insulative layer includes a film or fabric of thermally reflective material that may or may not be laminated to bubble sheets, foam or other insulative products. Optionally, the partition may further include straps or pockets or other releasably connecting devices that allow an on-site installer to add supplemental insulation materials to the partition in order to comply with local regulatory requirements with respect to insulation performance.

As stated above, attic stairways are extremely energy inefficient. They are typically made with a thin (½ in or less) sheet of plywood. They are drafty and allow significant energy loss of conditioned (either heated or cooled) air year round, and they typically allow for easy movement of air between the conditioned and un-conditioned attic space. This is not desirable.

The insulated building partition herein is made from weather barrier materials that are layered in a manner to create a higher R factor (good insulation performance) that is air and moisture tight and whereby the more delicate, inside thermally reflective layer is protected. The design of the partition is air tight, including a water and draft resistant attachment strip such as a zipper. The installed partition is significantly airtight covering an entire opening (whether that opening is to an attic or a crawl space or roof access). While the partition design allows a property owner or homeowner to enter and exit through the zippered opening, when zippered shut, the partition is a completely functional barrier to energy loss. The design allows the installer to select the R factor required by adding bat insulation or other insulation materials to the cover. The partition is built to be operated with one hand so the other can help keep the user steady on the stairs and is thus safer.

The insulated building partition is a laminate of weatherproofing, draft barrier and insulation material where not only is the reflective layer of insulation protected by tough textiles, but it also is designed with the ability of the installer to vary R factor. The partition will now be discussed in terms of the specific layers that may be used to form the partition. It is understood that additional features may optionally be added or developed to improve upon a specific design.

The outside layers are described together. These layers are typically arbitrarily designated “inside” and “outside” although they make up the outer layers of the partition. The outside layer designates the side of the partition that is facing the external space outside of the conditioned space or outside the building. The inside layer would face the inside or occupied and conditioned portion of a building. These layers can be formed from any fabric or film including, but not limited to the following,—knitted, woven or nonwoven fabrics, and films, all formed from natural or synthetic materials such as polyethylene, polyester, polypropylene, vinyl, cotton, hemp, and composites and mixtures thereof. This material may itself be water (and humidity) and air impermeable or resistant. Alternatively, the material may be coated with PVC or other flexible polymer material. One or more of these layers may be further reinforced with fibers or webbing or mesh to improve the toughness and durability of those protective layers. These protective layers may be pigmented or otherwise printed with indicia or wording to inform a user with respect to the partition location and use or for other informative reasons.

The insulative layer is secured in between the outside protective layers. The insulative layer may be secured in between by sewing or adhesive or heat bonding or other securing together of the laminate partition. This insulative layer may itself be formed of laminate layers of materials. This layer has at least one thermally reflective layer. The thermally reflective material may be a metal foil, a metal-coated polymer film, a reflective bubble material or it may be formed of another material that has thermal reflective properties. This thermally reflective layer may be enhanced with the addition of other insulation layers in between the outside protective layers. These added insulation layers may include bubble insulation, fiberglass, foam (open or closed cell) or cellulose or combinations thereof. There may be two or more layers of the thermally reflective material or additional insulation. For instance, this insulative layer may be one-eighth to two inches thick, or alternatively about one-quarter to one inch thick. The layer may have three thermally reflective layers that sandwich two bubble insulation layers therebetween. Alternatively, a polyurethane foam may be injected onto or in between layers of this insulation layer to enhance the overall insulation. Because the thermally reflective layers can be relatively weak and subject to tearing or breaking, this layer is secured between the outside protective layers described earlier.

Either the inside (facing the occupied or condition portion of the building) and/or the outside (facing the outside or external space of a building) protective layers may further include straps, pockets, sleeves, snaps, hooks, hook and loop fasteners, or other attaching mechanisms whereby supplemental insulation materials may be secured to the inside and or outside faces of the partition. As an example, straps that are elastic may be anchored to the partition. Supplemental insulation in the form or fiberglass or polymer fiber or cellulose or foam may be positioned next to the partition and held into place by those straps. This way, for an installation that requires extra insulation, the same basic barrier may be installed while the installer can increase the R-factor with supplemental insulation. Since insulation requirements can vary widely by geography, location of installation and local regulation, it is advantageous to have this built-in structure that allows the insulation to be increased if needed. The supplemental insulation can be fabricated in predetermined sizes and thicknesses to fit into pockets on the partition, for instance, with predetermined incremental improvements in R-factor. Or, the straps on the partition can be versatile enough to engage and secure a wide range of sizes and thicknesses of supplemental insulation material.

The partition also may include flanges and at least one fastener strip. The flanges may be made with the full, three-later construction described herein with respect to the insulating cover, or the flanges may just be made with one or two layers of durable fabric or film. The flange is secured around much or all of the outer perimeter of the partition. The flange is the portion of the partition that is secured to building structure that is around the building opening that the partition is covering. Typically, this flange portion is about several inches in surface width to be able to adequately secure the partition to the building around the opening.

The fastener strip, typically a zipper, is fixed between the insulated portion of the partition and the flange, which may or may not be also insulated. The zipper may be affixed anywhere necessary to allow the user to open the partition and enter the unconditioned space. The zipper provides a secure and water-tight/air-tight, or at least resistant, seal around the opening. The zipper is typically two-sided in that there are both inside and outside tabs, although a single tab on the inside or occupied side of the partition is all that is required. The fastener strip may be a zipper as discussed, but it may also be a hook and look fastener strip, snaps, buttons or other effective releasable attachment mechanisms.

The physical structure of the partition can be varied during manufacture depending on the specific intended location of the partition. Typically, the opening that is desired to be partitioned for insulation purposes will be completely covered by an insulated portion of the partition. Structurally, the partition is designed to be larger than the opening so that the flange portion of the partition will be able to overlap most or all of the perimeter of the building opening. In the example of an attic stair opening, those openings may range in size from at least 16 to 30 inches in width to at least 48 to 60 inches in length. These dimensions could of course be larger and smaller in some uncommon situations. The partition could be approximately 6 to 12 inches greater in both width and length so that the flange has enough material to comfortable overlap and lay on the floor or joists or studs that define the opening. Naturally, specific opening sizes may be accounted for in the examples of crawlspace openings, leaky windows and fan/air conditioner spaces. It is thermally important that the length and width or other shape dimensions of the partition are close to or greater than the opening dimensions so that the flange is greater than much or all of the opening perimeter. The zipper location is generally proximate or substantially the same as the perimeter shape and outline. In the rectangular attic stair opening example, the zipper is positioned around three sides of the rectangle so that a flap is created that enables simple access to an attic.

The present insulated barrier partition improves on the insular quality. It improves upon safety as is can be operated from the floor. It improves on ease of entry because the zipper is fixed evenly to the multilayer sheet of the partition. It improves upon design as it contains a radiant thermal barrier but protects this layer. And it is permanently installed and substantially airtight.

Example Partition

An example of a building partition includes the following components.

-   -   1. 420 PU coated Nylon as an outside layer     -   2. Two-sided, thermally reflective film and bubble insulated         fabric.     -   3. 9 mil reflective tarpaulin material or PVC vinyl material as         an inside layer.     -   4. Waterproof, rubber coated canvas and poly zipper—Or whatever         other zipper has the property of being weatherproof, such as         nylon coil zippers.     -   5. Elastic bat straps—can be any elastic material in many         different configurations just such that it holds steady and in         place a secondary source of insulation and (r-factor)like batt         insulation or foam board to the top of the partition product         and/or the sides.

Items 1, 2, 3, 4 and 5 are sewn together in their mathematical sequence. Then, the entire device is installed in one example with adhesive and screws or staples or other fastening device over an attic stairway door directly to the floor or support joists surrounding the attic door framing. For insulation purposes, a good seal of the flange around the opening will improve the insulation performance of the partition.

The flange may be cut to get around joists, trusses or cross members within the unconditioned space. The flange is the attachment layer. The zipper component layer is positioned in a vertical dimension of the device to allow the device to rest over an attic ladder. When an attic ladder is in the closed position and folded up, the ladders can take up space within the attic unless the framing creates a cavity in the attic floor to cover the vertical height of the ladder. In this case a no-flange partition may be installed.

The 420 PU coated nylon outside layer provides an air barrier and an extremely strong material to sew into for strength. The two-sided bubble insulated heat reflective fabric provides an r factor for thermal insulation and stability/rigidity for the final product. The PVC vinyl outside layer provides another air barrier as well as vapor barrier, as well as insulation and a pliable but also extremely strong material to sew into for strength and it heals over stitches because of its rubber type texture thus making the holes created by the sewing leak no or less air. The zipper provides an airtight opening to allow entry and exit for the user. The batt straps provide for a variable r-factor to meet regulatory requirements for new construction or where a permit is pulled and an inspector will require a certain local r-factor or compliance with ICC, federal, DOE or other local regulations whatever they may be at the time.

In order to fabricate the partition, a person must cut the materials to the desired dimension based on the attic stairway opening and the frame around it. Then he must layer the materials and attach the materials by sewing them together around the outer edge or alternatively use some other attachment methodology such as glue or heated textile welding. The zipper opening must be cut to a dimension that will allow the attic zipper to open and allow the user to move through. The zipper must be attached into place.

The 420 PU coated nylon and tarpaulin and heat reflective insulated shield layers are necessary. Additional layers of double sided heat reflective material or aerogel or mineral wool or other material can be included inside the partition to add r factor. The materials, #1, #2, or #2 and #3 can be inverted with no r-factor consequence and there would be the same functionality, but the reflective material would be visible from within the house but would function the same except it would be exposed. Putting #2 in the middles gives advantage because it is a more delicate material and in the partition configuration it is protected from tearing.

In use, the partition is installed with its flanges directly onto the floor of the attic if there is an attic floor. If not, a user may fold the flange either over the joists that contain the attic ladder framing or directly into the framing of the attic ladder. The installation can be done either way when there is no attic floor. The partition is typically installed with both high quality adhesive and a staple gun. The device is used by unzipping the zipper to obtain access to the attic and zippered shut to cut off energy loss through the attic stairway or attic hatch opening and prevent all drafts. As already noted, the partition could also be used for leaky windows and leaky doors.

Turning now to the attached figures, there are shown several alternative embodiments of the insulated partition. FIG. 1 shows an assembled insulating partition 10. The partition 10 includes an insulated cover 12, a flange 14 and a fastener strip 16, in this example a zipper. In this view, the perimeter flange 14 is shown facing upwardly. The insulated cover 12 is stepped and extends upwardly. This rectangular insulated cover 12 is sized generally to correspond to an attic (or other) opening. A zipper 16 is shown and extends around three sides of the raised or offset center cover 12. The zipper 16 has a two-sided zipper tab 18 to enable zipper access on both sides of the partition 10. This way, a user can open and gain access to the attic or alternatively can zip the partition shut to seal and insulate the opening. The partition cover 12 is a multi-layer sheet that is stitched together to secure three or more protective and insulating layers against and with each other. Glue or rivets or other connecting devices may alternatively or additionally be used to hold the partition cover 12 together.

FIG. 1 also illustrates a functional advantage of the zipper 16 mounted on the partition 10 cover 12. As shown, the zipper 16 is fixed on opposites sides to a first portion 15 and second portion 17 of the multilayer sheet that makes up the cover 12. The length of the two sides shown of the cover 12 is L1 plus L2. The length of the zipper 16 and also of the first and second portions 15 and 17 of the multilayer sheet cover 12 is also equal to L1 plus L2. This means that the zipper 16 does not have any sideways or lateral affixation to the cover 12 multilayer sheet. This way, the zipper 16 operates smoothly along its length by not having to move in the sideways or lateral direction to the zipper direction. Other zipper constructions are all coplanar and effect curves to open and close around rectangular openings. In those situations, the corresponding first and second attachment portions are a different length with one side being the inside diameter and the opposite side being an outside diameter. The zipping process with these coplanar constructions creates lateral forces that can bind or make more difficult the zipping and unzipping process.

FIG. 2 displays an insulated partition 20 mounted onto an attic floor 21 around an opening 22 that has a ladder 23 up to the opening. The partition 20 includes a flange 25 that is attached by glue or other fastener (not shown) to the attic floor 21. The partition 20 includes an insulating cover 24 having a zipper 27 that connects three sides of the cover to the flange 25. In FIG. 2, the cover 24 is shown unzipped around three sides to allow a person to move through the opening 22 in to and out of the attic.

FIGS. 3-5 illustrate different, alternative insulated layers that may be used to fabricate the insulated covers 12 and 24 shown in FIGS. 1 and 2 respectively. In FIG. 3, there is shown an insulated sheet 30 that includes a single bubble sheet 36 and a thermally reflective layer 38 in between outside protective layers 32 and 34. As explained earlier herein, the bubble sheet 36 is optional. The thermally reflective layer 38 can be a metal foil or a metal-coated film.

In FIG. 4, the multi-layer insulated sheet 40 includes two thermally reflective layers 47 and 48 attached or laminated to both sides of a bubble sheet 46. These inside layers 46, 47 and 48 are secured in between outside protective layers 42 and 44.

In a third example of an insulated sheet 50, FIG. 5 illustrates a five-layer inside portion where two bubble layers 56 and 57 are sandwiched between three thermally reflective film layers 58, 59 and 60. This inside portion is then secured between outside protective layers 52 and 54. Naturally, different insulation requirements may be called for depending on a building architecture and the surrounding geography. Different amounts of insulation as shown in alternative example in FIGS. 3, 4 and 5 illustrate some options with respect to how this insulation requirement may be met.

Finally, FIGS. 6 and 7 illustrate the embodiment of a partition where the partition has straps (FIG. 6) or pockets (FIG. 7) that may be optionally used to attach additional insulation materials to the partition. In FIG. 6, an insulated partition 65 includes a cover 70, flange 67 and a zipper 69. Straps 75 are attached at anchors 72 to the outside-facing surface of the cover 70. The straps 75 are intended to be used to secure additional insulating material (not shown) onto the cover 70 to increase the insulation capacity or R factor of the overall partition 65. The straps 75 include a sliding buckle to tighten down on added insulation material. Those straps 75 could alternatively be elastic to secure the extra insulation on the partition.

FIG. 7 illustrates another example of an insulated partition 80. The partition 80 includes a cover 86, a flange 82 and a zipper 84 connecting the cover to the flange. On the outside facing surface of the cover 86 there are two pockets 88. These pockets 88 are intended to be used to secure additional insulating material (not shown) onto the cover 86 to increase the insulation capacity or R factor of the overall partition 80. One or more pockets may be engineered for use. The size of the pockets may be varied. The pocket material may optionally include elastic material to stretch around inserts of varying sizes of extra insulation material.

FIGS. 6 and 7 illustrate straps 75 and pockets 88 respectively. Other mechanisms of attachment of additional insulating material to a cover could alternatively be chosen for use. These other attachment mechanisms include snaps, hook and loop fastener strips/patches, hooks, glue and any other mechanism or combination of mechanisms that allow an installer to meet the individual needs of a specific installation.

Other embodiments of the present invention will be apparent to those skilled in the art from consideration of the specification. It is intended that the specification and figures be considered as exemplary only, with a true scope and spirit of the invention being indicated by the claims. 

That which is claimed is:
 1. An insulated building partition comprising: a multilayer sheet sized to cover an opening in a building, the sheet having a perimeter defined by the outside edge of the sheet, the sheet comprising an insulated cover, a flange, and a fastener strip; wherein the insulated cover having a first inside layer of thermally reflective material between two outside protective layers of moisture resistant and relatively air impermeable materials; wherein the flange comprises the portion of the sheet begins at the perimeter of the sheet and extends inwardly from the perimeter around the sheet to an inside of the flange; wherein the fastener strip is positioned between the insulated cover and the flange around at least a majority of the perimeter of the sheet, the fastener strip allowing the insulated cover to be both separated from and alternatively secured to the inside of the flange; further wherein one of the two outside protective layers has a supplemental attachment mechanism positioned thereon, wherein the supplemental attachment mechanism is adapted to secure a second insulating material to the outside of the outside protective layer of the cover; whereby an insulation rating of the partition may be varied depending on the amount of second insulation material that may be secured to the partition.
 2. An insulated building partition as described in claim 1, the insulated cover further comprising a first insulating layer positioned in between the outer protective layers and adjacent the thermally reflective material layer.
 3. An insulated building partition as described in claim 2, the insulated cover further comprising a second inside layer of thermally reflective material positioned on the opposite side of the first insulating layer from the first thermally reflective material layer.
 4. An insulated building partition as described in claim 1, wherein thermally reflective material layer is selected from the group consisting of a metal foil and a metal-coated polymer film.
 5. An insulated building partition as described in claim 1, wherein the outside protective layers are formed of a material selected from the group consisting of knitted, woven or nonwoven fabrics and films formed from natural or synthetic materials including polyethylene, polyester, polypropylene, vinyl, cotton, hemp, and composites and mixtures thereof.
 6. An insulated building partition as described in claim 1, wherein the fastener strip is a zipper.
 7. An insulated building partition as described in claim 1, wherein the fastener strip is a hook and loop fastener structure.
 8. An insulated building partition as described in claim 1, wherein the flange comprises three layers including two outside protective layers around an inside thermally reflective material layer.
 9. An insulated building partition as described in claim 1, wherein the supplemental attachment mechanism is selected from the group consisting of a pocket, strap, sleeve, hook and loop fastener, snaps and hooks.
 10. An insulated building partition as described in claim 1, wherein the fastener strip is a zipper having a two-sided zipper tab.
 11. An insulated building partition as described in claim 6, wherein the zipper is fastened to the sheet on opposite sides to a first portion and second portion of the sheet, and the length of the zipper and the first and second portions is the same. 